ESAB QRC™-2000 Nozzle Cleaning Station Installation guide

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NOZZLE CLEANING

STATION

Installation and Operation

Guide

English

Français

Español

QRC

TM

-2000

Revision No: A Issue Date: November 17, 2008 Manual No: SM-QRC-2000

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Congratulations on your new Tweco

®

Robotics product. We are proud

to have you as our customer and will strive to provide you with the

best service and reliability in the industry. This product is backed by

our extensive warranty and world-wide service network. To locate your

nearest distributor or service agency, please contact a representative at

the address and phone number in your area listed on the inside back

cover of this manual, or visit us on the web at www.tweco.com.

This Operating Manual has been designed to instruct you on the correct

use and operation of your Tweco

®

Robotics product. Your satisfaction

with this product and its safe operation is our ultimate concern.

Therefore, please take the time to read the entire manual, especially the

Safety Precautions. They will help you to avoid potential hazards that

may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Tweco

®

Robotics is a Global Brand of Arc Welding Products for

Thermadyne Industries Inc. We manufacture and supply to major

welding industry sectors worldwide including; Manufacturing,

Construction, Mining, Automotive, Aerospace, Engineering, Rural and

DIY/Hobbyist.

We distinguish ourselves from our competition through market-leading,

dependable products that have stood the test of time. We pride ourselves

on technical innovation, competitive prices, excellent delivery, superior

customer service and technical support, together with excellence in

sales and marketing expertise.

Above all, we are committed to develop technologically advanced

products to achieve a safer working environment within the welding

industry.

WE APPRECIATE YOUR BUSINESS!

WARNING

READ AND UNDERSTAND THIS ENTIRE MANUAL AND YOUR EMPLOYER’S SAFETY PRACTICES BEFORE INSTALLING,

OPERATING, OR SERVICING THE EQUIPMENT.

WHILE THE INFORMATION CONTAINED IN THIS MANUAL REPRESENTS THE MANUFACTURER’S BEST JUDGMENT, THE

MANUFACTURER ASSUMES NO LIABILITY FOR ITS USE.

Nozzle Cleaning Station

Installation and Operation Guide

Instruction Manual Number SM-QRC-2000

Published by:

Tweco

®

Products Inc.

2800 Airport Road

Denton, TX 76208

(940) 566-2000

www.tweco.com

Thermadyne Industries Inc.

®

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any

error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: November 17, 2008

Record the following information for Warranty purposes:

Where Purchased: ________________________

Purchase Date: ________________________

Equipment Serial #: ________________________

i

nozzle cleaning station

ii

SM-QRC-2000

Table of Contents

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS .......................................... 1-3

1.01 Welding Hazards .......................................................................................1-3

1.02 Principal Safety Standards ........................................................................1-5

1.03 Safety and Health ......................................................................................1-5

SECTION 2: INTRODUCTION AND DESCRIPTION ................................................. 2-6

2.01 How to Use this Manual ............................................................................2-6

2.02 Receipt of Equipment ................................................................................2-6

2.03 Introduction ..............................................................................................2-6

SECTION 3: INSTALLATION AND OPERATION ..................................................... 3-7

3.01 Installation ................................................................................................3-7

3.02 Mounting the QRC

TM

-2000 Nozzle Cleaning Station ..................................3-7

3.03 Air Supply, Connections, and Lubrication Requirements ..........................3-8

3.04 QRC

TM

-2000 Wiring Interface ....................................................................3-8

3.05 Electrical and Pneumatic Controls Access ................................................3-9

3.06 Logic Inverse ............................................................................................3-9

3.07 LED Indicators ..........................................................................................3-9

3.08 Reamer Blade and Clamp Block Selection ...............................................3-10

3.09 Tweco

®

Robotic Nozzles vs. Clamp Block ...............................................3-11

3.10 Air Flow Control Valve .............................................................................3-11

3.11 Nozzle and Insertion Parameter ..............................................................3-11

SECTION 4: WIRING AND PNEUMATIC ............................................................

4-13

4.01 Wiring for the QRM-100 and QRM-3 Anti-spatter Mist Applicator .........4-13

4.02 Wiring Diagram .......................................................................................4-13

4.03 Pneumatic Diagram .................................................................................4-14

4.03 QRM-100 and QRM-3 .............................................................................4-14

SECTION 5: MAINTENANCE .........................................................................

5-15

5.01 Maintenance Schedule ............................................................................5-15

5.02 Component Replacement Instructions ....................................................5-15

5.03 Manual Setup ..........................................................................................5-17

SECTION 6: TROUBLESHOOTING ..................................................................

6-18

SECTION 7: REPLACEMENT PARTS ................................................................

7-19

STATEMENT OF WARRANTY ........................................................................

8-20

WARRANTY SCHEDULE .............................................................................

8-21

nozzle cleaning station

1-3

SM-QRC-2000

SAFETY INSTRUCTIONS AND WARNINGS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

SERIOUS INJURY OR DEATH MAY RESULT IF WELDING AND CUTTING EQUIPMENT IS NOT PROPERLY INSTALLED,

USED AND MAINTAINED. MISUSE OF THIS EQUIPMENT AND OTHER UNSAFE PRACTICES CAN BE HAZARDOUS. THE

OPERATOR, SUPERVISOR, AND HELPER MUST READ AND UNDERSTAND THE FOLLOWING SAFETY WARNINGS AND

INSTRUCTIONS BEFORE INSTALLING OR USING ANY WELDING OR CUTTING EQUIPMENT.

THE WELDING AND CUTTING PROCESS IS USED IN MANY POTENTIALLY DANGEROUS ENVIRONMENTS SUCH

AS ELEVATED HEIGHTS, AREAS OF LIMITED VENTILATION, CLOSE QUARTERS, AROUND WATER, IN HOSTILE

ENVIRONMENTS, ETC., AND IT IS IMPORTANT THAT THE OPERATOR(S) ARE AWARE OF THE DANGERS ASSOCIATED

WITH WORKING IN THESE TYPES OF CONDITIONS. BE CERTAIN THAT THE OPERATOR(S) ARE TRAINED IN

SAFE PRACTICES FOR ENVIRONMENTS IN WHICH THEY ARE EXPECTED TO WORK AND UNDER COMPETENT

SUPERVISION.

IT IS ESSENTIAL THAT THE OPERATOR, SUPERVISOR AND ALL OTHER PERSONNEL IN THE WORK AREA ARE AWARE

OF THE DANGERS OF THE WELDING OR CUTTING PROCESS. TRAINING AND PROPER SUPERVISION ARE IMPORTANT

FOR A SAFE WORK PLACE. KEEP THESE INSTRUCTIONS FOR FUTURE USE. ADDITIONAL RECOMMENDED SAFETY

AND OPERATING INFORMATION IS REFERENCED IN EACH SECTION.

5. All ground connections must be checked periodically

to determine that they are mechanically strong and

electrically adequate for the required current.

6. When engaged in alternating current, welding, or

cutting under wet conditions or warm surroundings

where perspiration is a factor, the use of reliable

automatic controls for reducing the no-load voltage

is recommended to reduce shock hazard.

7. When the welding or cutting process requires values of

open circuit voltages in alternating current machines

higher than 80 volts, and direct current machines

higher than 100 volts, means must be provided to

prevent the operator from making accidental contact

with the high voltage by adequate insulation or other

means.

8. When welding is to be suspended for any substantial

length of time, such as during lunch or overnight,

all electrodes should be removed from the electrode

holder and the electrode holder carefully located so

that accidental contact cannot occur.

9. The holder must be disconnected from the power

source when not in use.

10.

Never immerse Mig-Guns, electrode holders, tig

torches, plasma torches, or electrodes in water.

WARNING

SMOKE, FUMES, AND GASES CAN BE DANGEROUS

TO YOUR HEALTH.

1.01 Welding Hazards

WARNING

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH.

INSTALL AND MAINTAIN EQUIPMENT IN ACCORDANCE

WITH THE NATIONAL ELECTRICAL CODE (NFPA 70)

AND LOCAL CODES. DO NOT SERVICE OR REPAIR

EQUIPMENT WITH POWER ON. DO NOT OPERATE

EQUIPMENT WITH PROTECTIVE INSULATORS

OR COVERS REMOVED. SERVICE OR REPAIR TO

EQUIPMENT MUST BE DONE BY A QUALIFIED REPAIR

TECHNICIAN, OR TRAINED PERSONNEL ONLY.

1. Do not touch live electrical parts.

2.

Do not touch an electrode with bare skin and electrical

ground at the same time.

3. Always keep welding gloves dry and in good

condition.

NOTE

Aluminized protective clothing can become

part of the electrical path.

4. Keep oxygen cylinders, chains, wire ropes, cranes,

hoists, and elevators away from any part of the

electrical path.

nozzle cleaning station

1-4

SM-QRC-2000

SAFETY INSTRUCTIONS AND WARNINGS

21. Flammable hair preparations should not be used when

welding or cutting. Wear ear plugs to protect ears from

sparks.

22. Where the work area permits, the operator should be

enclosed in an individual booth painted with a ﬁnish of

low reﬂectivity such as zinc oxide. This is an important

factor for absorbing ultraviolet radiations, and lamp black.

The operator should be enclosed with non-combustible

screens similarly painted.

WARNING

WELDING SPARKS CAN CAUSE FIRES AND

EXPLOSIONS.

23. Causes of ﬁre and explosion are: combustibles reached by

the arc, ﬂame, ﬂying sparks, hot slag, or heated material.

Remove combustibles from the work area and/or provide

a ﬁre watch.

24

. Avoid oily or greasy clothing as sparks may ignite them. Have

a ﬁre extinguisher nearby, and know how to use it.

25.

Be alert to the danger of conduction or radiation. For

example, if welding or cutting is to be done on a metal

wall, partition, ceiling, or roof, precautions must be taken

to prevent ignition of combustibles on the other side.

26. Do not w

eld or cut containers that have held combustibles.

All hollow spaces, cavities and containers should be vented

prior to welding or cutting to permit the escape of air or

gases. Purging with inert gas is recommended.

27.

Never use oxygen in a welding torch. Use only inert

gases or inert gas mixes as required by the process. Use

of combustible compressed gases can cause explosions

resulting in personal injury or death. Arcing against any

compressed gas cylinder can cause cylinder damage or

explosion.

WARNING

NOISE CAN DAMAGE HEARING.

28. Noise from the air carbon-arc process can damage

your hearing. Wear protective hearing devices to ensure

protection when noise levels exceed OSHA standards.

Adequate hearing protection devices must be worn by

operators and surrounding personnel to ensure personal

protection against noise.

11. Keep smoke, fumes, and gases from the breathing area.

12. Fumes from the welding or cutting process are of various

types and strengths, depending on the kind of base metal

being worked on. To ensure your safety, do not breathe

these fumes.

13. Ventilation must be adequate to remove smoke, fumes,

and gases during the operation to protect operators and

other personnel in the area.

14. Vapors of chlorinated solvents can form the toxic gas

“Phosgene” when exposed to ultraviolet radiation from

an electric arc. All solvents, degreasers, and potential

sources of these vapors must be removed from the work

area.

15. Fumes produced by welding or cutting, particularly in

conﬁned places, can cause discomfort and physical harm

if inhaled over an extended period of time.

16. Provide adequate ventilation in the welding or cutting area.

Use air-supplied respirators if ventilation is not adequate

to remove all fumes and gases. Never ventilate with

oxygen. Oxygen supports and vigorously accelerates

ﬁre.

WARNING

ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE

EYES AND BURN SKIN .

17. The welding and cutting processes produces extreme

localized heat and strong ultraviolet rays.

18. Never attempt to weld or cut without a welding helmet

with the proper lens. Ensure that the lens complies with

federal guidelines. A number 12 to 14 shade ﬁlter lens

provides the best protection against arc radiation. When

in a conﬁned area, prevent the reﬂected arc rays from

entering around the helmet.

19. Ensure all personnel in the work area are protected from

arc rays and sparks. Approved shielding curtains and

appropriate goggles should be used to provide protection

to staff in the surrounding area and operators of nearby

equipment.

20. Unprotected skin should also be covered from arc rays,

heat and molten metal. Always wear protective gloves and

clothing that does not allow skin to become exposed. All

pockets should be closed and cuffs sewn shut. Leather

aprons, sleeves, leggings, etc., should be worn for out-of-

position welding and cutting or for heavy operations using

large electrodes. High top work shoes provide adequate

protection from foot burns. For added protection use

leather spats.

nozzle cleaning station

1-5

SM-QRC-2000

SAFETY INSTRUCTIONS AND WARNINGS

1.02 Principal Safety Standards

1.03 Safety and Health

NOTE

Be sure to read and fully comprehend the safety

instuctions and warnings contained within

section 1 of this manual before performing

any welding or cutting operations.

WARNING

SERIOUS INJURY OR DEATH MAY RESULT IF

WELDING AND CUTTING EQUIPMENT IS NOT

PROPERLY INSTALLED, USED, AND MAINTAINED.

MISUSE OF THIS EQUIPMENT, OR OTHER UNSAFE

PRACTICES, CAN BE HAZARDOUS.

Electric shock can cause injury or death.

Smoke, fumes, and gases can be dangerous to your

health.

Arc rays, hot slag, and sparks can injure or burn

unprotected eyes and skin.

Welding sparks can cause ﬁres and explosions.

Excessive noise can damage your hearing.

•

SAFETY AND OPERATING REFERENCES

1. Code of Federal Regulations. (OSHA)

Section 29 Part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254 and 1000.

U.S. Government Printing Ofﬁce, Washington, DC. 20402.

2. ANSl Z49.1 “Safety In Welding and Cutting”.

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.

4. ANSl Z88.2 “Standard Practice for Respiratory Protection”.

American National Standards Institute, 1430 Broadway, New York, NY. 10018.

5. AWS F4.1 “Recommended Safe Practices for Welding and Cutting Containers”.

6. AWS C5.3 “Recommended Practices for Air Carbon-Arc Gouging and Cutting”.

The American Welding Society, 550 NW Lejeune RD., P.O.Box 351040, Miami FL. 33135.

7. NFPA 51B “Fire Prevention in Cutting and Welding Processes”.

8. NFPA-7 “National Electrical Code”.

National Fire Protection Association, Battery Park, Quincy, MA. 02269.

9. CSA W117.2, “Safety in Welding, Cutting and Allied Processes”.

Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.

Warning

This producT conTains chemicals, including

lead, or oTherWise produces chemicals knoWn

To The sTaTe of california To cause cancer,

birTh defecTs and oTher reproducTive harm.

W a s h h a n d s a f t e r h a n d l i n g .

(california healTh & safeTy code § 25249.5 eT

seq.)

nozzle cleaning station

2-6

SM-QRC-2000

INTRODUCTION AND DESCRIPTION

2.01 How to Use this Manual

To ensure safe operation, read the entire manual, including

the chapters on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION,

and NOTE may appear. Pay particular attention to the

information provided under these headings. These special

anNotetions are easily recognized as follows:

WARNING

A WARNING GIVES INFORMATION REGARDING

POSSIBLE PERSONAL INJURY.

CAUTION

A CAUTION refers to possible equipment

damage.

NOTE

A NOTE offers helpful information concerning

certain operating procedures.

2.02 Receipt of Equipment

When you receive the equipment, check it against the

invoice to make sure it is complete and inspect the

equipment for possible damage due to shipping. If there is

any damage, notify the carrier immediately to ﬁle a claim.

Furnish complete information concerning damage claims

or shipping errors to the location in your area listed in the

inside back cover of this manual. Include a full description

of the parts in error.

If you want additional or replacement copies of this CD,

please contact Tweco

®

Robotics at the address and phone

number in your area listed on the inside back cover of this

manual. Include the Manual number (from page i) and

CD part number: CDROBOTICS.

SECTION 2:

INTRODUCTION AND DESCRIPTION

2.03 Introduction

Before installing or operating the QRC

TM

-2000 Nozzle

Cleaning Station, please read and understand all safety

precautions included with this product and instructions

listed in this manual. Failure to follow all instructions and

safety warnings can result in personal injury or equipment

damage.

The Tweco

®

Robotics QRC

TM

-2000 Nozzle Cleaning Station

was designed to provide the user with high quality nozzle/

tip cleaning that ﬁts well in a robotic work cell. This durable

product is a proven performer in the rigorous environment

associated with a continuous operating robotic station.

nozzle cleaning station

3-7

SM-QRC-2000

INSTALLATION AND OPERATION

SECTION 3:

INSTALLATION AND OPERATION

3.01 Installation

The Tweco

®

Robotics QRC

TM

-2000 Nozzle Cleaning Station

is easy to install. The following are instructions to aid in

mounting and making all necessary connections to your

cleaning station. If you have any questions concerning

these instructions, contact Tweco

®

Robotics Technical

Services for further assistance.

3.02 Mounting the QRC

TM

-2000 Nozzle

Cleaning Station

Install the nozzle cleaning station inside the robot work

cell to make it easy to access. The nozzle cleaning station

should be mounted to allow easy access to the robot arm,

but in a manner that will not interfere with other operations

like loading and unloading ﬁxtures. The drawing shows the

hole pattern required to mount the QRC

TM

-2000 as well as

important clearance dimensions.

The nozzle cleaning station is mounted using four 3/8”

diameter bolts in the holes provided on the base. The unit

should be leveled.

13.1

[334]

16.4

[416]

17.8

[452]

9.8

[249]

4.3

[108]

1.4

[36]

RESET

SWITCH

16.4

[416]

IN

[mm]

.625

[15,88]

.500

[12,7]

5.000

[127]

3.78

[96,01]

1.319

[33,5]

.590

[14,99]

8.088

[205,44]

8.465

[215,01]

9.000

[228,6]

IN

[mm]

.968

[24,59]

2.500

[63.5]

Figure 1

IN

[mm]

nozzle cleaning station

3-8

SM-QRC-2000

INSTALLATION AND OPERATION

3.03 Air Supply, Connections, and

Lubrication Requirements

The air supply for the QRC

TM

-2000 nozzle cleaning station

should be ﬁltered, unlubricated air. This unit requires 80-

100 PSI @ 8 CFM (5.5 – 6.8 BAR @ 225 LPM). The air

supply line should be a minimum of 1/4” I.D. with a male

1/4” NPT connection to ﬁt the female connection in the

side of the logic cover. The air motor is lubricated through

a servo meter located below the lubricator reservoir.

The servo meter injects a quantity of oil directly into

the solenoid valves and air motor during each cleaning

cycle. The lubrication should be done using a light grade

hydraulic oil with a viscosity rating of 150 VC 15-20 (SAE

5W). When ﬁlling the reservoir for the ﬁrst time or reﬁlling

an empty reservoir, you must manually prime the pump to

distribute the oil through the system. The servo meter has

an adjustment that goes from 0 (-) to 45 (+) clicks and a

push button to prime the lubricant oil. Refer to Figure 2.

Pull the servo meter knob to the unlock position (A).

Set the servo meter knob at 45 (+) and press the button

appromimately 50 to 60 times.

Turn the servo meter knob counter-clockwise to 0 (-)

and set at 3 (+) clicks.

Push the servo meter knob back into the locked position (C).

The amount of lubricant can be adjusted by turning the

adjustment knob located on the servo meter.

•

LUBRICATOR

RESERVOIR

SERVO

METER

Figure 2

SERVO

METER

KNOB

PRIMER

PUSH

BUTTON

NOTE

Do not run unit without lubricant oil. If unit runs

out of lubricant oil, the motor will lock up and

the solenoid valves will stick. When lubricant

oil is added you must prime the unit and check

operation of the solenoid valves. Permanent

damage can be caused to the solenoid valves if

the unit is allowed to run out of lubricant oil.

NOTE

Lubricator Reservoir oil must have a vent in the

open position. If not, oil will not ﬂow.

3.04 QRC

TM

-2000 Wiring Interface

The QRC

TM

-2000 Nozzle Cleaning Station wiring interface

requires a ﬁve wire connection. Each wire is color-coded.

The drawing below shows the wire color to its connector

pin/socket number and function.

The Following Connections are Required for Proper

Unit Operation:

Red Lead Connection: Operates internal logic with

a +24 V DC supply.

Green Lead Connection: Cycle complete output

signal (+24 V DC for sourcing logic signal; 0 V DC

for sinking logic signal).

White Lead Connection: Supply common.

Orange Lead Connection: Cycle start input signal

+24 V DC for sourcing logic signal; 0 V DC for sinking

logic signal. (.5 - 1.0 second pulse signal)

Black Lead: Spare wire (optional connection).

•

NOTE

The QRC2000 nozzle cleaning station is factory

preset at 3 (+) clicks.

TURN

(ADJUST)

RED: +24 VOLTS DC SUPPLY

GREEN: UNCLAMP SYMBOL

WHITE: SUPPLY COMMON

ORANGE: +24 VOLTS DC START SIGNAL

BLACK: SPARE/OPTION

4. START SIGNAL

(ORANGE)

5. OPTION

(BLACK)

ENSURE PROPER INTERFACE HAS BEEN MADE OR DAMAGE

MAY OCCUR

2. +24 VDC

SUPPLY (READ)

1. COMMON

(WHITE)

3. JAWS UNCLAMPED

(GREEN)

Figure 3

ROBOTIC

CONTROL

nozzle cleaning station

3-9

SM-QRC-2000

INSTALLATION AND OPERATION

3.05 Electrical and Pneumatic Controls

Access

Ensure that the power is off and disconnected, and air

supply is off before removing logic cover.

To gain access to the circuit board and pneumatic manifold,

the logic cover must be removed. To free the logic cover

loosen four 10-24 button head screws and slide cover

away from cleaning station being careful not to disconnect

the interface connections from circuit board.

3.06 Logic Inverse

The QRC

TM

-2000 Nozzle Cleaning Station comes from the

factory set for sourcing (high) +24 V DC input or output.

Some installations may require the opposite of this or 0

V DC sinking (low) input or output.

Accessing the circuit board is necessary to switch from

sourcing to sinking input/output. On the lower right hand

corner of the circuit board are two switches that need to be

set to correspond to the input/output signal requirement

as shown.

CAUTION

Do not switch circuit board sourcing and

sinking switches with power on. Damage will

occur. Only move switches with power off.

To operate the unit ON sinking connection, switch SW1

must be in the down position, and switch SW2 must

be in the up position. To operate the unit ON sourcing

connection, reverse the position of the switches. Refer

to diagram shown on Figure 5.

SW2

SWITCH 2 (SW2) OUTPUT

JAWS UNCLAMPED

SINKING (UP)

SOURCING (DOWN)

SOURCING (UP)

SINKING (DOWN)

SWITCH 1 (SW1) INPUT START

SIGNAL

SW1

Figure 5

3.07 LED Indicators

The LED indicators located on the side of the logic

cover, supply visual information regarding cycle status.

This information may be used for both installation and

maintenance to verify proper operation. The LED indicates

the cleaning sequence as follows:

Unclamped - On

Indicates that the clamp cylinder is fully extended, opening

the nozzle clamp block and supplying an output signal that

the reamer cycle is complete.

Reamer Ahead - Off

Indicates that the lift cylinder is fully extended putting the

reamer blade at the top of its reaming stroke and activating

the upper limit switch on the circuit board.

Reamer Home - On

Indicates that the lift cylinder has fully retracted, placing

the reamer blade at the bottom of its stroke (home

position), and has activated the lower limit switch on the

circuit board.

NOTE

Both the

Unclamped

and

Reamer Home Lights

must be on for the unit to start the cleaning

process.

CLEANING SEQUENCE

UNCLAMPED

REAMER AHEAD

REAMER HOME

CAUTION

ENSURE PROPER INTERFACE

HAS BEEN MADE OR DAMAGE

MAY OCCUR. READ TECHNICAL

GUIDE BEFORE START-UP.

Figure 6

LOGIC

COVER

NO. 10-24

X 1/2” LG.

BUTTON

HEAD

SCREW

(4 EA.)

SOLENOID

VALVE (2 EA)

CIRCUIT

BOARD

NO. 10-24

X 1/2” LG.

BUTTON

HEAD

SCREW (4

EA.)

NO.

10X1/2”

LG

THREAD

FORMING

SCREW

(2 EA)

Figure 4

nozzle cleaning station

3-10

SM-QRC-2000

INSTALLATION AND OPERATION

3.08 Reamer Blade and Clamp Block

Selection

To ensure that proper nozzle and tip cleaning occurs

without loss of tip alignment, each application must be

customized to ﬁt the speciﬁc robotic gun, contact tip, and

nozzle conﬁguration. The chart below will help you select

the best reamer blade for your particular application. The

reamer blade O.D. (outside diameter) selected will depend

on the I.D. (inside diameter) of the nozzle being used. The

reamer blade I.D. used would depend on the O.D. of the

contact tip. All QRC

TM

-2000 Nozzle Cleaning Stations come

from Tweco

®

Robotics with the QRC

TM

-100 reamer blade

(.620”/15,7mm O.D. x .422” / 10,7mm I.D.).

Figure 7

Part No. Stock No. Reamer

O.D. (A)

Reamer

I.D. (B)

Reamer

Length (C)

Nozzle

Bore

Contact Tip

QRC-100 3500-1275 .620” (15,7mm) .422” (10,7mm) 1.25” (31,7mm) 5/8” (15,9mm) A, B, C, & D

QRC-101 3500-1276 .494” (12,5mm) .344” (8,7mm) 1.25” (31,7mm) 1/2” (12,7mm) A & B

QRC-102 3500-1277 .485” (12,3mm) .344” (8,7mm) 1.12” (28,4mm) 1/2” (12,7mm) A & B

QRC-103 3500-1278 .368” (9,3mm) .281” (7,1mm) .94” (23,8mm) 3/8” (9,5mm) A

QRC-104 3500-1279 .734” (18,6mm) .530” (13,5mm) 2.08” (52,8mm) 3/4” (19,1mm) A, B, C, & D

QRC-105 3500-1280 .620” (15,7mm) .344” (8,7mm) 1.25” (31,7mm) 5/8” (15,9mm) A & B

QRC-106 3500-1290 .368” (9,3mm) .270” (6,9mm) .94” (23,8mm) 3/8” (9,5mm) A

QRC-107 3500-1281 .604” (15,3mm) .438” (11,1mm) 1.25” (31,7mm) 5/8” (15,9mm) A, B, C, & D

QRC-108 3500-1282 .505” (12,8mm) .344” (8,7mm) 1.27” (32,2mm) 5/8” (15,9mm) A & B

QRC-109 3500-1283 .620” (15,7mm) .344” (8,7mm) 1.25” (31,7mm) 5/8” (15,9mm) A & B

QRC-110 3500-1284 .620” (15,7mm) .296” (7,5mm) 1.25” (31,7mm) 5/8” (15,9mm) A & B

QRC-111 3500-1285 .734” (18,6mm) .296” (7,5mm) 1.84” (46,7mm) 3/4” (19,1mm) A & B

QRC-112 3500-1286 .620” (15,7mm) .360” (9,1mm) 1.00” (25,4mm) 5/8” (15,9mm) A, B, & C

QRC-113 3500-1287 .734” (18,6mm) .360” (9,1mm) 1.84” (46,7mm) 3/4” (19,1mm) A, B, & C

QRC-114 3500-1288 .620” (15,7mm) .390” (9,9mm) 1.25” (31,7mm) 5/8” (15,9mm) A, B, C, & D

QRC-115 3500-1289 .734” (18,6mm) .390” (9,9mm) 1.84” (46,7mm) 3/4” (19,1mm) A, B, C, & D

QRC-116 3500-1291 .494” (12,5mm) .359” (9,12mm) 1.08” (27,4mm) 1/2” (12,7mm) A, B, & C

QRC-119 3500-1297 .620” (15,7mm) .312” (7,9mm) 1.053” (26,7mm) 5/8” (15,9mm) A & B

QRC-120 3500-1298 .620” (15,7mm) .312” (7,9mm) 1.128” (28,6mm) 5/8” (15,9mm) A & B

QRC-121 3500-1299 .485” (12,3mm) .312” (7,9mm) .73” (18,5mm) 1/2” (12,7mm) A & B

QRC-121S 3500-1274 .485” (12,3mm) .374” (9,5mm) .84” (21,3mm) 1/2” (12,7mm) A, B, & C

QRC-122 3500-1260 .620” (15,7mm) .390” (9,9mm) 1.25” (31,7mm) 5/8” (15,9mm) A, B, C, & D

QRC-123 3500-1261 .552” (14,2mm) .390” (9,9mm) 2.26” (57,4mm) 5/8” (15,9mm) A, B, C, & D

QRC-124 3500-1262 .485” (12,3mm) .344” (8,7mm) ?.84” (21,3mm) 1/2” (12,7mm) A & B

QRC-125 3500-1259 .485” (12,3mm) .390” (9,9mm) 1.25” (31,7mm) 1/2” (12,7mm) A, B, C, & D

QRC-126 3500-1258 .485” (12,3mm) .360” (9,1mm) 1.08” (27,4mm) 1/2” (12,7mm) A, B, C

QRC-127 3500-1253 .528” (13,4mm) .360” (9,1mm) 1.08” (27,4mm) 5/8” (15,9mm) A, B, C

QRC-ABZ 3500-1273 Adapter for use on Binzel cleaning station in order to use Tweco

®

Robotics reamer blades.

Contact Tips (Reference Table 1)

A 11, 14, 14T, EL11 & AL (O.D. = .250” / 6,3mm)

B 11H, 11RS, 14H. 14RS, 14RZ & AL (O.D. = .283” / 7,1mm)

C EL16, EL16RS, & AL (O.D. = .345” / 8,7mm)

D

16S, 16RS, 16RZ & AL (O.D. = .375” / 9,5mm)

Table 1: QRC

TM

-2000 Reamer Blades List

nozzle cleaning station

3-11

SM-QRC-2000

INSTALLATION AND OPERATION

The other variable part in the QRC

TM

-2000 Nozzle Cleaning

Station is the clamp block set. There are ﬁve clamp blocks

available. Please refer to Tables 2 and 3.

The clamp block “B” comes assembled on all QRC

TM

-2000

Nozzle Cleaning Station. Clamp blocks A, C, D, and E are

also supplied with the unit.

Table 2: QRC

TM

-2000 Clamp Blocks List

Clamp Block O. D. Fits Nizzels

QRC2102-A .938” (23,8mm)

QRC2102-B 1” (25,4mm)

QRC2102-C 1.062” (27,0mm)

QRC2102-D 1.125” (28,6mm)

QRC2102-E .875” (22,2mm)

QRC2102-F .787” (20,0mm)

Table 3: Tweco

®

Robotic Nozzles vs. Clamp Block

Nozzle Nozzle O.D. Clamp Block

REL21 Series .875” (22,2mm) QRC-2102-E

REL24CT Series 1” (25,4mm) QRC-2102-B

RWC24 Series 1” (25,4mm) QRC-2102-B

RWC26 Series 1.062” (27,0mm) QRC-2102-C

3.09 Tweco

®

Robotic Nozzles vs. Clamp Block

Program the robot to position the Mig nozzle directly above

and centered to the reamer blade above the QRC

TM

-2000.

Insert the nozzle to the required depth to allow complete

cleaning of the tip and nozzle without damaging the torch

consumable parts. (Please refer to section 3.11).

At this time the cycle start signal (pulse .5 to 1.0 seconds)

should be sent to the QRC

TM

-2000 from the robotic

controller. Then the QRC

TM

-2000 will clamp the nozzle and

perform the cleaning operation.

Once the reamer completes the cleaning cycle, the cleaning

station will send a cycle complete signal back to the robot

controller. At this time, the torch is removed from the

QRC

TM

-2000 and the work cycle continues.

3.10 Air Flow Control Valve

The air ﬂow control valve provides an adjustment for the

reamer blade feed rate. The amount of spatter buildup

will determine the required reamer blade feed rate. The

heavier the spatter, the slower the reamer blade feed

rate that should be used. If a smaller amount of spatter

accumulates, the feed rate can be set faster.

Adjusting the air ﬂow control valve:

There is an air ﬂow control valve inside the unit as

shown in Figure 8.

The feed rate may require adjusting for different

applications.

•

ADJUSTING

KNOB

LOCKING

NUT

INCREASE

FEED RATE

DECREASE

FEED RATE

Figure 8

3.11 Nozzle and Insertion Parameter

All QRC

TM

-2000 Nozzle Cleaning Stations come from

Tweco

®

Robotics with the QRC-100 reamer blade

(.620”/15,7mm O.D. x .422” / 10,7mm I.D.) and clamp

block “B” (QRC2102-B / 1”(25,4mm)).

Please make sure that the reamer blade and clamp block

ﬁt the need of your application.

Setting up the Torch with Gauges

There are three sizes of gauges (1/2” (12,7mm), 5/8”

(15,9mm) and 3/4” (19,1mm)). These gauges are

available as a set under Part No. QRC

TM

-PG2.

Determine O.D. of reamer blade being used.

Slip proper gauge on O.D. of reamer blade.

Screw in tip index shaft.

Determine O.D. of contact tip being used.

Slip proper alignment sleeve on pointer.

Bring torch down to where the I.D. of contact tip

touches pointer, push alignment sleeve up and over

contact tip to gauge if torch is set at 90 degrees.

Once this is established, back the torch off from the

pointer to allow room to remove the pointer and

alignment sleeve.

Bring the torch back down to where the nozzle

touches top of the gauge.

This allows the programmer to set up for the stroke

of the reamer blade in the cleaning sequence.

NOTE

Using a ﬂush or protruded nozzle, adjust the

reamer blade stroke, leaving a gap between

the nozzle and the top of the gauge. For

flush nozzles: leave a 1/8” (3,2mm) gap.

For protruded nozzles: leave a 1/4” (6,4mm)

gap.

•

To increase the reamer blade feed rate, unscrew the

nut and rotate the valve knob counter-clockwise.

After the adjustment, lock the valve knob nut.

To decrease the reamer blade feed rate, unscrew the

nut and rotate the valve knob clockwise. After the

adjustment, lock the valve knob nut.

•

nozzle cleaning station

3-12

SM-QRC-2000

INSTALLATION AND OPERATION

CONTACT TIP

ALIGNMENT SLEEVE

TIP INDEX SHAFT

PROGRAMMING GAUGE

REAMER BLADE

NOZZLE

PROGRAMMING

GAUGE

REAMER BLADE

Figure 9

Figure 10

nozzle cleaning station

4-13

SM-QRC-2000

WIRING AND PNEUMATIC

SECTION 4:

WIRING AND PNEUMATIC

4.01 Wiring for the QRM-100 and QRM-3 Anti-spatter Mist Applicator

The drawings below show the QRM-100 and QRM-3 wiring connections.

For a sinking connection, the wires must be connected to positions 5 and 2. For sourcing connection, the wires

must be connected to positions 5 and 3.

To operate the QRM-100 Anti-Spatter Mist Applicator, a timed 24 V DC signal must be applied to the black lead

(spare) of the interface receptacle.

•

MOTOR & CLAMP

SOLENOID VALVE

SPINDLE LIFT

SOLENOID VALVE

PIN #5

PIN #3

ANTISPATTER UNIT

24DC

MOTOR & CLAMP

SOLENOID VALVE

SPINDLE LIFT

SOLENOID VALVE

PIN #5

PIN #2

ANTISPATTER UNIT

24DC

SOURCING SINKING

4.02 Wiring Diagram

Figure 12

LOWER LIMIT

SWITCH

UPPER LIMIT

SWITCH

CLAMP

RETURN LIMIT

SWITCH

NOT USED

START SIGNAL

COMMON

+24VDC

JAWS UNCLAMPED

OPTIONAL EQUIPMENT

SEE 5 PIN

CONNECTOR

WIRING

RESET SWITCH

MOTOR AND CLAMP

SOLENOID VALVE

SPINDLE LIFT

SOLENOID VALVE

OPTIONAL

EQUIPMENT

PIN #4

(ORG) START

SIGNAL

PIN #5 (BLK)

OPTION

PIN #3

(GRN) JAWS

UNCLAMPED

PIN #2 (RED)

+24 VDC

PIN #1 (WHT)

COMMON

EXTERNAL VIEW OF 5-PIN CONNECTOR

Figure 11: Pin #1 on Top/Pin #6 on Bottom

nozzle cleaning station

4-14

SM-QRC-2000

WIRING AND PNEUMATIC

4.03 Pneumatic Diagram

Figure 13

1/8-27 NPT X 5/32

TUBE ELBOW

1/4-18 NPT X 1/4

TUBE ELBOW

1/4-18 NPT X 1/4

TUBE ADAPTER

FEED RATE

CONTROL

10-32 X 5/32

TUBE ADAPTER

1/8-27 NPT X 1/4

TUBE ELBOW

(5 EA.)

1/4-18 NPT X 1/4

TUBE ELBOW

5/32 TUBE X 5/32

TUBE ELBOW

1/4 TUBE X 1/4

TUBE ELBOW

1/4 TUBE “Y”

CONNECTOR

Figure 14: QRM-100 Figure 15: QRM-3

4.03 QRM-100 and QRM-3

nozzle cleaning station

5-15

SM-QRC-2000

MAINTENANCE

SECTION 5:

MAINTENANCE

5.01 Maintenance Schedule

The QRC

TM

-2000 will require a periodic maintenance

schedule to ensure an optimum service life. The following

maintenance checks are required. Depending on the use

of the unit, each speciﬁc application could require a more

extensive schedule.

Daily

Ensure incline housing area is clear of excessive

spatter.

Visually check oil level in lubricator reservoir.

Weekly

Ensure incline housing area is clear of excessive

spatter.

Visually check lubricating oil level in lubricator

reservoir. The life of the air motor is dependent on

a sufﬁcient supply of lubricating oil. Replenish this

oil as needed.

Inspect air lines and connections for leaks.

Check interface cables for frayed connections or

bad wiring.

Quarterly

The QRC

TM

-2000 reamer blade life will depend on the

application.

At least quarterly the reamer blade should be inspected

for dullness, clogging and breakage.

Visually check lubricating oil level in lubricator reservoir.

Ensure incline housing area is clear of excessive spatter.

Yearly

The clamp block should be cleaned and inspected

for excessive wear and replaced if needed.

Visually check lubricating oil level in lubricator

reservoir. Replenish this oil as needed.

Inspect air lines and connections for leaks.

Check interface cables for frayed connections or

bad wiring.

Remove top plate and apply grease on cam slides

on top (V-Block) and side plates.

•

5.02 Component Replacement Instructions

Upper, Lower, and Jaw Stop Limit Switches

Ensure that the power is off and disconnected, and the air

supply is off before replacing the limit switches.

To replace the limit switches, loosen the screws that

connect the limit switch bracket to the manifold.

Disconnect the wiring for the limit switch that is being

replaced.

Remove the nut that connects the limit switch to the limit

switch bracket.

Replace the limit switches in reverse order

•

NOTE

Be sure to review the wiring diagram when

rewiring and disconnecting the limit switch (see

Figure 12). The limit switches are adjusted at

the factory. If an adjustment needs to be made,

please contact our factory technical center.

Reset Switch

Unscrew the nut that connects the limit switch to

bracket.

Disconnect the wiring from the circuit board and

replace it.

NOTE

Be sure to review the wiring diagram (Figure

12) when rewiring and disconnecting the reset

switch.

•

Circuit Board

Ensure that the power and air supply are off and

disconnected before replacing the circuit board.

Replace the circuit board in the following manner:

Once the power and air are disconnected from the

QRC

TM

-2000, carefully unplug all connectors from

the board.

Unscrew the two screws located on the circuit board.

(Fig. 17) The circuit board can now be replaced.

Install the new circuit board on the board insulator.

Once this has been completed, tighten the two circuit

board mounting screws.

Reconnect the connectors while referring to wiring

diagram to be sure the connections are in the

proper location.

CAUTION

Do not switch circuit board sourcing and

sinking switches with the power on. Damage

will occur. Only move the switches with the

power off.

•

LOWER

LIMIT

SWITCH

BRACKET

SCREW

LOCKING

NUT

SWITCH

BRACKET

JAW CLAMP

LIMIT

SWITCH

RESET

SWITCH

UPPER LIMIT

SWITCH

Figure 16

nozzle cleaning station

5-16

SM-QRC-2000

MAINTENANCE

Clamp Block

Ensure that the power and air supply are off and

disconnected before replacing the clamp block.

Certain applications or normal wear may cause the need

to replace the QRC

TM

-2000 clamp block. There are ﬁve

clamp blocks available.

CIRCUIT BOARD

INSULATOR

NO. 10 S 1/2” LG.

THREAD-FORMING

SCREW (2 EA.)

SW1 SWITCH

SW2 SWITCH

CIRCUIT

BOARD

J5

CONNECTOR

Figure 17

J4 CONNECTOR

J3 CONNECTOR

J1 CONNECTOR

J2 CONNECTOR

Table 4: ORC

TM

-2000 Clamp Blocks List

Clamp Block O.D. Fits Nozzles

QRC2102-A .938” (23,8mm)

QRC2102-B 1” (25,4mm)

QRC2102-C 1.062” (27,0mm)

QRC2102-D 1.125” (28,6mm)

QRC2102-E .875” (22,2mm)

QRC2102-F .787” (20,0mm)

Clamp block “B” comes assembled on all QRC

TM

-2000

Nozzle Cleaning Station. The clamp blocks A, C, D, and E

are also supplied with the unit.

LOCATOR SPACER

CLAMP BLOCK

LOCATOR PIN

REAMER BLADE

TOP PLATE

SCREWS (7 EA)

Figure 18

Remove the seven screws on three top plate.

Remove the top plate to the cleaning station.

Lift and rotate the clamp block so that the desired

sizes face the jaws.

Clean the components thoroughly and lubricate with

grease before reassembling them.

NOTE

Part numbers are stamped on clamp blocks.

Please refer to Table 4 - QRC

TM

2000 clamp

block list for the outside diameter of the

nozzle.

•

QRC

TM

-2000 Reamer Blade

To remove the reamer blade, place the 9/16” (14mm)

spanner wrench, part no. QRC-440, on the hex ﬂats

at the end of the extension shaft and the QRC-441

wrench on the top of the reamer blade.

The cutter is removed by turning counterclockwise

when viewed from above. Considerable force may be

required to loosen the reamer blade since it tightens

naturally as the reamer operates.

Please refer to Table 1 for reamer blade options.

•

T-WRENCH

REAMER BLADE

9/16” SPANNER

WRENCH

Figure 19

nozzle cleaning station

5-17

SM-QRC-2000

MAINTENANCE

Air Solenoids

Ensure that the power is off and disconnected, and air

supply is off before replacing the air solenoids.

Refer to section 5.02 to remove the circuit board.

Remove and replace one solenoid at a time. Unscrew

the two screws on the air solenoid and unplug the

wire connectors.

Remove solenoid.

Install the new solenoid with the gasket and rewire.

Repeat sequence for the other air solenoid.

•

NOTE

Be sure to review the wiring and pneumatic

diagram when rewiring and disconnecting air

solenoids.

GASKET

AIR SOLENOID

M3 X 0.5 SCREW

AIR SOLENOID

ELECTRICAL

WIRES

Figure 20

5.03 Manual Setup

To manually operate the QRC

TM

-2000 Nozzle Cleaning

Station without electricity, connect air in proper place and

manually activate the two air valve buttons located on the

solenoid valves.

Each solenoid valve has a red button. Manually press each

button to activate the unit.

A) The left air valve button activates the up and

down lift movement of the reamer blade.

B) The right air valve button activates the spin and

clamp.

NOTE

The reset button should be pressed prior to

manual setup to reset all circuitry.

SOLENOID

VALVE

LEFT BUTTON ACTIVATES

(REAMER BLADE UP AND

DOWN)

RIGHT BUTTON

ACTIVATES (SPIN AND

CLAMP)

Figure 21

nozzle cleaning station

6-18

SM-QRC-2000

TROUBLESHOOTING

SECTION 6:

TROUBLESHOOTING

Problem Cause Solution

LED signals not activating

1. The unit is not receiving power. 1. Turn power on.

2. The unit is not getting air. 2. Turn air on.

3. Input voltage is incorrect. 3. Check input voltage and change if

required.

Reamer Blade/Air Motor stops

during operation (see also

Pneumatic functions not operating

properly)

1. Cutter feed rate is too fast. 1. Reduce cutter feed rate (see

section 3.10).

2. Excessive spatter buildup. 2. Clean affected area and adjust weld

parameters. Apply or increase

anti-spatter. Clean more often.

3. Incorrect air supply. 3. Adjust air supply (See section

3.03).

Pneumatic functions not operating

properly

1. Incorrect air supply. 1. Adjust air supply (see section

3.03).

2. Air line damage or obstructed and

air leaks.

2. Check lines for leaks and replace

hose if damaged.

3. Faulty reset switch. 3. Repair or replace reset switch.

Broken Reamer Blade

1. Wrong size reamer blade or clamp

block.

1. Check sizing (see section 3.08).

2. Reamer blade feed rate was set

too high.

2. Reduce cutter feed rate. (see

section 3.10).

3. Excessive spatter buildup. 3. Clean affected area and adjust weld

parameters. Apply or increase

anti-spatter. Clean more often.

Reamer Blade stays in down position

1. Damaged lift cylinder or air lines. 1. Reset switch defective.

2. Faulty or contaminated lift solenoid. 2. Check solenoid valves. Fix or

replace faulty solenoid.

3. Reset switch defective. 3. Replace reset switch.

4. Damaged limit switch. 4. Identify and replace faulty

switch.

Reamer Blade stays in up position

1. Reamer Blade is jammed. 1. Press Reset button and Inspect

Reamer Blade.

2. Faulty air solenoid. 2. Replace air solenoid.

3. Bad or dirty lift cylinder. 3. Fix or replace cylinder.

4. Cycle start signal held on. 4. Adjust cleaning cycle program.

5. Faulty limit switch. 5. Replace limit switch.

Cycle complete signal does not

activate

1. Faulty limit switch on lift cylinder

or clamping cylinder.

1. R epl ac e or r ea li gn r ead

switch(es).

2. Unit is not wired correctly. 2. Check wiring (see section 4).

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